Metallic wall and roof joint



y 0, 1956 R. K. M BERTY 2,753,962

' METALLIC WALL AND ROOF JOINT Filed Sept. 15, 1950 s Sheets-Sheet 1xii-33% s, I f

y IN VEN TOR.

ATTOPNfYS y 10, 1956 R. K. M BERTY 2,753,962

METALLIC WALL AND ROOF JOINT Filed Sept. 15, 1950 6 Sheets-Sheet 2 QINVENTOR.

July 10, 1956 McBERTY 2,753,962

METALLIC WALL AND ROOF JOINT Filed Sept. 15, 1950 6 Sheets-Sheet 3ours/05 FIN/5H 72E PAPEQ HVSULA 7' ION INVENTOR. B05597 K M65627) A77'OPA/EYJ July 10, 1956 R. K. M BERTY METALLIC WALL AND ROOF JOINT 6Sheets-Sheet 4 Filed Sept. 15, 1950 INVENTOR fiil y" B05527 K MceerrJuly 10, 1956 R. K. McBER 2,753,962

METALLIC WALL AND ROOF JOINT I Filed Sept. 15, 1950 6 Sheets-Sheet 5INVENTUR. POBEET A. M65677V E/VEYJ July 10, 1956 R. K. MCBERTY METALLICWALL AND ROOF JOINT 6 Sheets-Sheet 6 Filed Sept. 15

/6 INVENTOR.

,eoaaer k. MC anarr A Tree/V575 United States Patent METALLIC WALL ANDROOF JOINT Robert K. McBerty, Galion, Ohio Application September 15,1950, Serial No. 184,929

3 Claims. (Cl. 189-1) This invention relates generally to a buildingstructure suitable for dwellings and other structures, as well as amethod of producing the same.

Briefly, the essence of my invention resides in the provision of areadily assembled, self-trueing frame construction of sheet metal,adapted to be covered with insulation and weather-proof finish surfaces.

In its broadest and most basic aspects, a building constructed inaccordance with my invention may be thought of as having for itsfundamental structural and enclosing elements an enclosed box ofrelatively thin continuous sheet metal reinforced against stresses oftension and compression by having fastened thereto at spaced intervalssheet metal column members. The elements are arranged so that all partsare built up of duplicates of a few similar pieces, and are self-trueingand have tight, strong joints. This light, inexpensive, andreadily-assembled basic structure serves to support, by means of thecolumn members, the inside and outside insulation and finish layers, anddue to the nature of the basic structure, virtually no metallic path forheat transfer between the outer and inner finish layers is provided.

Where the roof panels are formed in the manner of the wall panels, theirjunction may be braced by box-like members bridging the rafter andcolumn elements.

More specifically, a Wall framework built up in accordance with saidpreferred embodiment will comprise a series of tubes or hollow columnsmade up of relatively thin sheet metal and spaced about two feet apartby webs of thin sheet metal rigidly interlocked with said columns. Theparts are adaptable and interchangeable and permit the production of awide variety of architectural and strucniral designs without specialengineering. I provide means whereby the central web and the columns maybe assembled by lateral motion without relative axial sliding of saidparts, there being locking means to fasten the columns and webs inassembled relationship that prevent relative axial sliding of the partsand so produce a rigid, self-tmeing framework. No additional braces orsupports are required during the assembly. I contemplate that thecolumns may be filled with cement, if so desired. Such a framework isnot only novel in itself, but gives a foundation for construction of awall having numerous advantages not found in the art.

Prior workers who have attempted to provide a building assembly of thetype to which this invention relates, have been forced to employ one ormore of several undesirable and expensive constructions in order toproduce an adequately rigid composite building structure, .one reasonbeing that the proposed basic frameworks were inherently unsatisfactoryand difiicult to assemble.

For example, some workers have conceived forming framework of metal.tubes or columns but have found it necessary .to make the columnssubstantially contiguous=" parts together laterally,

in order to obtain the desired strength and rigidity. This is not onlyan expensive construction but complicates the fittings of doors,windows, and the like.

Others have improved upon the above-mentioned structure by using spacedcolumns but have employed sheet metal members to form the inside andoutside wall surfaces in order to impart the necessary accuracy andrigidity to the framework during assembly. This is not only an expensiveconstruction, diificult to assemble, but it is subject to the seriousdisadvantage that there is excessive heat conduction from one sheetmetal wall to the other wall.

Still others have attempted to provide column-like members with websthere between, but because the webs do not form a self-trueing rigidstructure with the columns they have found it necessary to pour concretebetween the columns, on at least one side of the web.

Accordingly, a primary object of my invention lies in making a readilyassembled, self-trueing sheet metal framework of web-spaced columns, apreferred form of which requires neither inner nor outer wall membersfor its support and alignment to add Weight and conduct heat. It is anobject to provide a framework that requires no concrete between thecolumns, and which may be assembled into a rigid aligned structurewithout requiring relative axial sliding of the major components,springing of parts in place, etc. Still anotherobject is to provide asimple readily-fabricated, strong, and easily assembled means and methodfor attaching sheets or Webs together -or to columns or reinforcingmembers formed of sheet material. These objects are attained and all ofthe aforesaid disadvantages of prior constructions I overcome in thepreferred embodiment by forming cylindrical COlllIlll'lS of thin sheetmetal, preferably semi-cylinders that have sideflanges withchannel-shaped tongues supported at-each side by the flanges. Theflanges are interlocked with thin sheet metal webs by assembling the norelative axial motion of the assembled parts being possible. In thepreferred construction, the parts are permanently joined together byreadily inserted axial keys, rods or other similar devices.

A further important object resides in the reduction of heat transferbetween the inner and outer walls to a minimum. This I accomplish byfastening spaced narrow horizontal strips or channels of sheet metal tothe tubes or columns, said strips serving the dual function of furtherreinforcing the wall and acting as mounting means for insulation,expanded metal lathe and the like. It is important to note that withthis construction, the inner and outer wall supporting strips are narrowso that they have little more than point contact with the columns. Thisreduces heat conduction from the warm wall to the cold wall to a minimumand virtually eliminates cold spots in the warm wall because the onlypath for heat transfer is from a series of points at one side to opposedpoints on the other side. A construction of this type requires nostiffening and locating metal webs that extend laterally from wall towall. Such webs, common in the prior art, facilitate heat transferbetween the walls and produce cold spots on of thin metal are hadwithout sacrifice of strength and rigidity. In order to attainself-trueing and rigidity of structure when using thin sheet metal forthe framework, it is highly important that the fastening means for thecolumn and webs prevent relative axial movement of those parts. Thisconstruction has an important advantage in that the sheet metalcomponents. may be made. of relatively thin material-without dangerbecause the tongues are supported at two sides by their flanges.- Thisonstruction is superior to prior arrangements wherein rive l or freetabs. are. used to. fasten the parts. because in the prior arrangementsthe fasteners must be extremely close together or the base metal quitethick to prevent tearing of the base metal.

Another object resides in. increasing the strength and rigidity of thebuilding structure where the rafters join the walls. This is,accomplished by providing box-like brace members connected to thecolumns and to. the rafters. Preferably the intermediate sheet metalwebs are bent to. extend. continuously over the corner at the roof.

It is also desirable, and an object of the invention, to place the websin. tension so. that they formv an. integral unit structure with. thecolumns, To this end I form the thin sheet metal columns so that theirdimension across the wall is less than. that in the wall, such as anoval section. Thus, if concrete is poured intothe columns, thehydrostatic pressure of the liquid. aggregate tends to expand the.columns in a direction normal tov the wall and. contract them in. theplane of the wall, for example if the columns are elliptical, theirminor axes will. be. elongated. This draws up on the webs and removesclearances in the joints, the resulting structure being remarkablystrong. and rigid even though quite thinmetal be employed. Althoughconcrete or the like is an excellent medium to elongate the minor axesof the columns, similar. results will be obtained by using structuralmembers slid into place after assembly, such as sheet metal webs.

Other objects and advantages reside in the provision of novel. baseassemblies for'- thecolumns and; webs,

effective and simple cap. structures for the wall, means wherebythe roofsection may be built according tothe principles of the invention andjoined to the wall section, and. provision of a framework which isadapted forthe reception of insulating material, or of heat' or .coolingpipes, water conduits and the like. It is a feature of the inventionthat warmed air may be circulated withinthe walls, ceilings,and-floorsfor heating purposes. The provision of a structure made up ofreadily-fabricated repetitiveparts that can be adapted or even made upin parton thejob, using relatively simple breaks, hand tools, shearsandpunches.

The manner in which the aforesaid objectsand adyantages may be attainedwill appear more fully in connection with the following detaileddescription of. the preferred embodiment of my invention accompanied byillustrated drawings thereof.

In the drawings;

Fig. 1 represents an exploded partial view ofthebasic elements that goto make up the wall framework of. the preferred embodiment;

Fig. 2 shows the same elements assembled With.portions broken .away. forclarity;v V

Fig. 3 is a. horizontal section through a wall section;

Fig. 3a is a horizontal sectional viewof the wall columns andillustrates'the I deformability of the columns upon being filled withconcrete.

Fig, ,4 is a perspective view of the longitudinal cap memberwhich maybe. assembledat the/top, ombottom of-the-wall.structure;- i

Fig. 5 illustrates how the cap member may-befastened to the columnmember; a

' the loops may be belled out to facilitate insertionof'th'e Fig. 6 is avertical section through the, wall framework intermediate the column;

Fig. 6a is a similar section with the lower section broken away to showhow the columns are set into the foundation;

Fig. 7 is a partial perspective View of the building with variousportions broken away to show how they are assembled;

Fig. 8 is a similar view shown when the roof structure may be assembledwith the wall structure;

Figs. 9 and 10 illustrate modified forms of wall structure;

Fig. 11 shows a modified form of Web and column assembly wherein the webis uninterrupted at one or more columns;

Fig. 12 shows a box-like reinforcing member for use between the columnsof the wall and roof;

Fig. 13 shows a modified form of wall and roof juncture, and,

Fig. 14 is a section taken on 1414 of Fig. 13.

Basic wall structure As is best seen in Fig. l, the preferred basic wallstructure is; composed of three fundamental elements. These elements area semi-cylindrical column member 10, a similar; member 11, and. an.intermediate web structure 12. Because of the novel way in which 'mybuilding is con. structed. and assembled, these basic members may bemade of quite thin. sheet metal. These elements may beeitherprefabricated or made up on the job, providing the proper breaksand. shears are at hand. The column member. 10 has side flanges 13,which. are joined to the body by channel-like tongues 14, preferablyshaped in the form of a. U, whichtongues may be formed byv pressing outthe base metal or by forming channels and punching out metalbetween.thetongues as at 15. C01.- umn member 11 has. sideflanges 16 which arepunched out at 17: for reception, of the tongues 14. The sheetmetaliwebs;12shaveflanges 18 to assist in initial locating of the parts;and; are punched out at 19 to receive the tongues-14; the tongues. andrecesses being axially complementary and providing abutment surfaces inplanes generally.- normal to the column axes. The manner in which. theparts are assembled is clearly illustrated in Fig. 2; The partsmay.be'assembled laterally so that tongue lAiextendsthroughaperture 19 inthe panel and 'windowframes, door.frames,.cabinets or the like.

Due to .frictionthat resists thrusting rod ZO-through a long row ofloops 14, the fit must be reasonably loose.

lithe-pieces are-held-reasonably inline; near the upper end, and ifthe-rod has a slightly tapered end, once the rodis started throughthefirst ofa row of loops, the other. loops-in order are brought in lineand pulled throughthe-flots, as the end of the-rod advances, much as azipper tab pulls the parts together.

The locking; rod may lie-forced" through aseries of loopsby pressure,bytwisting, in which case a coarse thread on the rod may beanadvantage,or; by pressure with vibrating pulses alongthe major axis, such as maybe produced'by-avibrating tool. The upper edges of rod.

It canbeseenthatthisbasic walljstructure has several advantages. First,due to the abutments between the loops and the edges-of the recesses theWallis selftrueing in that no relative axial movement or canting of theparts is possible, and the keys positively prevent relative lateralmotion. Next, the parts are readily assembled by being brought intoengagement laterally, as opposed to a construction where columns andwebs are assembled by axial sliding of one element into the other whichbecomes almost impossible unless parts are either very loose orperfectly aligned. Also, the tongues 14 are connected to the associatedcolumn member at both ends, rather than at one end. This greatly adds tothe strength of the assembly and permits the use of thin metal.

Plate and cap structure Another feature of my invention resides in theunusually simple and effective means provided for supporting the wall onthe foundation. As seen in Figs. 6a and 7, I may place an inverted capmember C in the founda tion before the concrete hardens to form a plate.Member C has lateral flanges 31, depending flanges 32 and is formed witha central channel 30 for reception of panel or web members 12, it beingnoted that the panels preferably protrude past the column members. Guideor pilot sleeve members are inserted in the foundation before theconcrete hardens, the plate member C being apertured as at 33 to receivethe sleeves. Pilot sleeve S includes extension 37 which reposes in theconcrete, an intermediate collar 38, and an upper extension 39 whichtelescopes within the associated column member. Thereupon, the wallsegments may be progressively assembled with each column surrounding asleeve member, and the key rods 20 driven home. Next, as seen in Figs.5, 6 and 8, a cap member C, like that reposing on the foundation, islaid across the tops of the column and panel members, with the panelsextending upward into the channel 30 of the cap. I prefer that thecolumn members protrude through apertures 33 so that the upper ends maybe cut to form ears 21 which are bent over to firmly assemble the parts.This is best seen in Fig. 5. A series of studs, pins or other fasteningdevices 35 are inserted through apertures in the column members andserve as hangers or fastening means for other parts of the buildingstructure. At this point, and if so desired, concrete may be poured intoeach column member, which can be readily accomplished because the upperends are open.

Roof structure After the column and webs are assembled together to formthe walls of the building, the roof structure will most likely be added.Fig. 8 illustrated how the principles of the invention just describedmay be carried forward to produce the roof structure. It is to beunderstood that my invention is not limited to the use of a roofstructure shown in Fig. 8, but my wall structure is adapted to receivethe roof structure therein illustrated. An elbowed guide sleeve S1 maybe provided for the upper end of each column member. Such a sleeve mayhave a pilot portion 45 telescoped within the column, it beingunderstood that if concrete fills the columns the sleeve would be fittedbefore the concrete hardened. A collar 46 locates the sleeve, and anelbow section 47 is formed to provide the proper pitch for the roof. Themembers corresponding to the conventional rafters may be made up ofcolumn members 10 and 11 fastened to panels 12a by keys 20, such membersfollowing the principles of construction just described. The columns areassembled to telescope over pilot portion 49 on the sleeves S1 and willbe axially located by collars 48. Strap or clamp members 48a may beadded to strengthen this part of the assembly. The intermediate webs 12aare assembled with the rafter members as described where they join thewall they may be flanged as at 50 and fastened to channels 30 of capmember C. Such channels are apertured as at 30a, and suitable fasteningemployed for attachment of the panels. With the construc tion outlined,the sheet metal may be quite thin, in the nature of A stock, although ifthe columns are not filled with concrete thicker metal may be desirable.

Insulation As seen in Figs. 7 and 8, the insulation should be next tothe outside surface of the webs and columns, and may be either loosefill of porous material, blanket-like organic or inorganic fibers, orsheets of insulating boards, or combination. The blanket-like materialas prepared may be wrapped over the outside of the steel frame, and byuse of waterproof adhesive, seal the walls from the outside air. It isto be understood that electric conduits and heating or cooling pipes mayrun vertically between the columns.

Furring strips A feature of the invention is the provision of narrowhorizontal channels 40 of sheet metal which are fastened to the columnsby means of studs or pins 35. These preferably take the form of channelsflattened at the columns so that they do not materially increase theoverall thickness of the wall. I prefer that these strips be long enoughto span at least two or more columns in which case they stiffen andstrengthen the structure even though the columns and webs are fabricatedof quite thin sheet metal. These strips may then act as furring stripsand may support sheets of tar paper, expanded metal lathe, or anyintermediate finishing material characteristic of the type ofconstruction desired. Alternately the furring strips may be prefastenedto sheets of wallboard, plywood, Transite, or the like in an alignedrelationship such that each assembly of furring strips and board isreadily attached to the columns as a unit.

The preferred outside finish is cement, sprayed onto a backing ofexpanded metal lath, with tar paper in back of that. This finish,approximately one-inch thick is adequate in strength, and of goodappearance. Alternatively, plywood, Masonite, Cellotex, asbestos-cementsheets, tiles, bricks, or other organic or inorganic material may beused for the outside finish. Metal sheets may also be used, being boltedto the upright columns, and the horizontal furring strips and cap andplate members.

Reduction in heat transfer As mentioned previously, one of the objectsof this invention resides in the elimination of cold spots in the walldue to heat conduction from one wall to another. It will be noted thatalthough a rigid self-aligning structure is produced, the onlyhorizontal elements extending laterally from wall to wall are the capmembers C. But these are either at the foundation or at the roof of eachstory, and, since in the completed building neither of these areas arephysically opposite occupied parts of the building (because of the floorand coiling structures), the heat transfer due to the cap members can beignored. Between the roof and ceiling, the only lateral path for heatconduction is at the fastening pins 35 and these points form aninsignificant portion of the total wall area. The strips 40 makesubstantially point contact with the columns and so that very littleheat is conducted to or from such strips. Furthermore, these strips mayoverlie the insulation so that heat must pass through pins 35. Thecolumns themselves are insulated from the outside of the wall by the tarpaper, lathe and finish coats of material and even so they make littlemore than point contact with the metal furring strips which supportthose walls. Furthermore, even from said points of contact the heat musttraverse a relatively long path to pass from one wall to another bymeans of the thin columns, thus, despite the fact that the basicframework of the building is of metal, and of a rigid construction, theheat conduction between walls by the metallic members is, to

all practical purposes no greater than that which would occur if theconventional wooden framework were employed.

Alternate form ofwall and roof construction As seen in Fig. 11, I maymake the webs 12c wide enough to extend completely past one or more ofthe column members so that the webs are uninterrupted at such members.The construction is otherwise like that shown in Figs. 1 and 2 whereinthe column members are formed up of channels and 11, each channel beingflanged and the channel 10 having tongues 14 struck therefrom thatextend through apertures in the web and in the flanges of the otherchannel 11, the parts being located together by rods essentially asdescribed.

In some structures where rigidity of the joint between the roof and thewall is of importance, the construction shown in Figs. 12 to 14 may beemployed, and in many respects this is the preferred construction. Aplurality of sheet metal box-like bracing members are formed having sidewalls 81, an inner or back wall 82, front flanges 83, top flanges 84angled to correspond to the pitch of the roof, and bottom flanges 86.The various flanges are punched or cut as at 87 to receive the tongues14 on the channel members 16. The assembly of the box member 80 with thewall columns and rafters appears clearly in Figs. 13 and 14, and it willbe noted that the member is readily attached into the framework at thesame time the other assemblies are attached by simply sliding rods 20through the tongues. Thus, the box members are firmly connected to thewall, to the roof, and to the beam member extending between the walls,thereby forming with these parts a very rigid braced corner. Thisconstruction facilitates making the web continuous at the corner becausethe web 12c need only be bent as at 88 and may be continued along aspart of the joint between the parts.

Additional features As seen in Fig. 3a, in forming the column members Imake them so that they cooperate to form an oval or ellipticalcross-section with the long axis in the plane of the web members. Withthis construction, when concrete is poured into the columns, the wallshaving the least spacing tend to spread and those in the plane of thewebs tend to approach one another. In other words, the cross-section ofthe columns tend to assume the circular form indicated at X, which drawsup on the joints and tensions the parts with a considerable increase inrigidity of the parts. The same result may be attained by sliding insheet metal pieces disposed along the minor axis of the columns.

As in wooden construction, it will be obvious to those skilled in theart that if additional rigidity is required, one or more column membersmay be inclined toform a braced construction, which provides anexceptionally rigid structure. Likewise, one or more members 40 may bewidened and fastened at two or more places to each column, to provideadditional bracin Furthermore, it will be obvious that some members 40may be applied diagonally to augment the rigidity of the structure.

The column and wall structure described previously is a preferredembodiment of the invention, but Figs. 9 and 10 illustrate modificationswhich have the same mode of operation and advantages asthe preferredembodiment. In Fig. 9 the column and intermediate walls are of atwo-piece rather than a three-piece construction.

For example, in Fig. 9 each section fill-has a wall or web part 61integral with oppositely disposed semi-column members 62. These columnmembers terminate in flanges 63 which flanges are apertured to receivepunched out tongue members 64', as shown. Key rods 20 fasten the partstogether in the manner previously described.

Fig. ltl'illustrat'es a modification similar to the structure shown inFig. 1. Two sections 11 are employed and tongues are all formed in, thewebs B. It will be seen that the tongues and 71 are struck from the websin opposite directions. A pair of key rods 20 will be required for eachside of the column in this construction. The mode of operation in thismodification is like that previously described and it offers all theadvantages thereof.

It will be understood that regardless of the nature of the locking meansemployed, webs between the column may be cut away to provide forwindows, doors, cupboards, and the like. An important advantage of theconstruction is that although the sheet metal components are relativelythin and light, the accuracy of the finished assembly inherent when theinvention is practiced permils the use of prefabricated window and doorframes, wallboard sections, etc. with a minimum of cutting and fittingon the job. Also, some saving in materials could be effected by formingthe webs as vertically-spaced sections to provide for door and windowframes. For example, narrow webs could be fastened to the columns at thetop and bottom of a given panel or wallsection at a saving of material,the only criterion being the strength and rigidity desired.

Although I prefer to connect the webs to the columns in the commonmidplane of the latter, it will be obvious that many of the advantagesand features of the invention will be effected if the webs are connectedtangent to the columns at one side thereof. A building con structed inaccordance with this invention is readily heated without requiringheating pipes or conduits, because warmed air may be circulated withinthe confines of the walls, the ceiling, and the floors to provide aneffective and economical heating system.

Having completed a detailed description of my invention and a preferredembodiment thereof, it will be understood by those skilled in the artthat various modifications having the mode of operation of the inventionmay be made, and, accordingly, I contemplate that the appended claimsand not the aforesaid embodiment be determinative of the scope of myinvention.

What is claimed is:

l. in a building wall and roof construction, a plurality of alignedcolumn and rafter members, said members comprising spaced thin sheetmetal tubular elements connected at their midplane to thin sheet metalweb elements, locking means on said elements connecting said webelements and said tubular elements, said locking means providingengaging abutment surfaces generally normal to the axis of said tubularelements making said assembly rigid and self-trueing and preventingaxial mo.- tion between said column members and said web elements, andbox-like members bridging said column and rafter members at theirjunction, said box-like members having flanges along the sides thereoffastened to said column and rafter members and said web elements by saidlocking means.

2. In a building wall and roof construction, a plurality of alignedcolumn and rafter members, said members comprising thin sheet metaltubular elements connected at their mid-plane to thin sheet metal webelement's, locking means on said elements connecting said webs andtubular elements, said locking means providing engaging abutmentsurfaces generally normal to the axis of said tubular elements makingsaid assembly rigid and self-trueing and preventing axial motion betweensaid tubular elements and said web elements and box-like membersbridging said column and rafter members at their junction, said box-likemembers having flanges along the sides thereof fastened to said tubularand web elements by said locking means, said web elements of the walland roof being continuous and extending across the joint at thecontiguous. ends of the columns and rafters.

3. In a building, a wall comprising a plurality of spaced thin sheetmetal column elements connected at their common mid-plane by thin sheetmetal web elements, locking means on said elements connecting said weband column elements, said locking means providing engaging abutmentsurfaces generally normal to the axes of said columns making saidassembly rigid and selftrueing and preventing axial motion between saidcolumn elements and web elements, key means engaging said locking meansand fastening said elements together, a roof having rafters extendingfrom said column elements with said rafters joined by web elements inthe manner just defined and box-like brace elements joined to andextending axially along said column elements and rafters at theirjunction, said brace elements having flanges on the sides thereofretained against said wall and roof by said key means.

References Cited in the file of this patent UNITED STATES PATENTSBahrmann May 27, Pruden May 27, Bell June 10, Reiner et a1. Aug. 21,Bemis Aug. 11, Schroeder Sept. 23, Graef May 12, Dalton Mar. 9, FullerJune 13, Battin Jan. 21, Rapp Sept. 9,

FOREIGN PATENTS Australia Apr. 7,

Great Britain Dec. 19,

